Advanced RGV system accepts operator data inputs

Transmissions manufacturer is using a rail-guided vehicle system that enables operators to enter process data directly into the RGV thus satisfying the strictest of data management requirements.

Turner Powertrain Systems, a division of the Caterpillar group, has recently taken delivery of the Mipas rail-guided vehicle (RGV) system to enhance the production assembly of their new TH-B transmission.

The assembly platform is based on the pioneering Mipas RGV technology developed by Eclipse Handling (EHL) based in Hemel Hempstead, Hertfordshire.

Mipas RGV is designed to challenge the overall flexibility and cost effectiveness of traditional centralised control methods.

By the nature of the design Turner's investment can now be aligned with their projected production demand as the new transmission establishes itself in the global market.

This is a significant breakthrough in product assembly planning and leapfrogs conventional philosophy into a new generation of assembly techniques.

The patented Mipas RGV system utilises a highly efficient brushless DC drive motor and uniquely designed, modular, control unit.

Each RGV also includes its own integrated PC with touch screen HMI.

This system enables operators to enter process data directly into the RGV thus satisfying the strictest of data management requirements.

The physical size of this particular component and complex assembly process proved a great challenge with the result being an RGV measuring 1.5 x 1.3m in size and incorporating a special location fixture with two separate powered axis of movement.

Using the onboard HMI, operators are able to rotate the 550Kg transmission through 360 deg of rotation in two horizontal planes.

This flexibility provides a solution to build the very complex component by enabling operators to effortlessly manipulate it in almost any position in any station.

The simple track design guides RGV's down two parallel runs, each having no mechanical moving parts.

To re-circulate the RGV's, EHL designed two special 'End Gate' mechanisms.

These helped reduce to overall floor area requirements making the whole production line a very compact and unrivalled design.

This makes the track extremely cost effective and gives customers the opportunity to have an entire track layout with a minimum of investment.

Turner's have initially taken delivery of 7 x RGV's with the provision for more to be supplied as their production demands dictate.

All the RGV's take their power from a super safe 24VAC supply connected by two sprung loaded collectors acting on a pair of conductor rails embedded in the guide track.

This system enables a single RGV to be added or removed without interfering with general production and provides and excellent means for maintenance.

When each RGV reaches a stop position power is automatically switched off, this assists in reducing energy consumption to virtually zero whilst the RGV is stationary, i.e majority of the time.

This specification includes numerous operator workstations, utilising D.C.

controlled electric handtools.

When a RGV carrying the transmission enters a workstation the onboard HMI automatically displays to the operator which derivative of component it is and what assembly is to be performed.

Using the tooling provided the operator carries out the work content.

It is possible to achieve direct communication between the tooling and the RGV as the operator works, however this has not yet been enabled but is due for introduction early next year.

This will provide an automatic Poka Yoke method of station control as only good assemblies will be allowed to proceed.

The RGV proceed instruction at present comes from the operator HMI which is depressed upon completion of the work content in the station.

When the transmission reaches the end of the line all the assembly data is downloaded and retained for the customer's records.

The escort memory is then cleared of all data and the process is again started with a new transmission.

Each RGV is fitted with an ultrasonic transceiver so as to ensure contact less buffering during the assembly process.

This again reduces energy consumption, as power to each individual RGV is automatically switched off when it comes up against an obstruction.

Power is reintroduced when the obstruction is removed.

EHL has commented, "The Mipas RGV philosophy challenges all aspects of traditional methods and boasts a whole host of benefits.

Areas such as running costs, maintenance, flexibility for expansion or modification, delivery lead times and tailor made financial packages have all been addressed in the development of this exciting new system".

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